Unitary heating element and heater assemblies, cartridges, and e-vapor devices including a unitary heating element

Abstract

A heating element for an e-vapor device includes a planar portion including at least one filament. The filament may define an air channel through the planar portion. The heating element may include first and second lead portions extending away from the planar portion. The planar portion, the first lead portion, and the second lead portion may be a unitary body.

It is claimed: 
     
         1 . A dual heating element for an e-vapor device, the dual heating element comprising:
 a first heating element, and   a second heating element stacked on the first heating element, each of the first and second heating elements including,
 a planar portion including a filament defining an air channel through a central portion of the planar portion, the filament extending in a circular shape about the air channel, the filament arranged so as to form a plurality of u-shaped portions extending radially from the air channel, and a first one of the plurality of u-shaped portions being beside a last one of the plurality of u-shaped portions, each of the plurality of u-shaped portions including a tip and an end section opposite the tip, the end section of each of the plurality of u-shaped portions adjacent the air channel, the end section of each of the plurality of u-shaped portions having a first width, and the tip of each of the plurality of u-shaped portions having a second width greater than the first width. 
   
     
     
         2 . The dual heating element of  claim 1 , wherein the first heating element and the second heating element are electrically connected via welding, soldering, or a pressure-based connection. 
     
     
         3 . The dual heating element of  claim 1 , wherein the tip of each of the plurality of u-shaped portions extends away from the air channel. 
     
     
         4 . The dual heating element of  claim 1 , wherein each of the first heating element and the second heating element further comprises:
 a first lead portion, and   a second lead portion, the first lead portion and the second lead portion extending away from the planar portion.   
     
     
         5 . The dual heating element of  claim 4 , wherein
 the planar portion, the first lead portion, and the second lead portion are a unitary body,   the first lead portion is connected to the first one of the plurality of u-shaped portions, and   the second lead portion is connected to the last one of the plurality of u-shaped portions, such that the first lead portion is beside the second lead portion at a point of connection to the planar portion.   
     
     
         6 . The dual heating element of  claim 4 , wherein the first lead portion and the second lead portion at least partially surround the planar portion. 
     
     
         7 . The dual heating element of  claim 4 , wherein
 the first lead portion includes a first tip,   the second lead portion includes a second tip, and   the first tip and the second tip are on opposite sides of the planar portion.   
     
     
         8 . The dual heating element of  claim 7 , wherein the first tip of the first lead portion and the second tip of the second lead portion are bent in a direction that is perpendicular to the planar portion. 
     
     
         9 . The dual heating element of  claim 1 , wherein a width of the filament varies along a length thereof. 
     
     
         10 . The dual heating element of  claim 9 , wherein the width of the filament gradually increases in a direction away from the air channel. 
     
     
         11 . The dual heating element of  claim 1 , wherein the u-shaped portions are connected to one another at the end sections of each u-shape. 
     
     
         12 . The dual heating element of  claim 1 , wherein a space between adjacent ones of the plurality of u-shaped portions gradually increases in a direction away from the air channel. 
     
     
         13 . The dual heating element of  claim 1 , wherein the filament includes stainless steel. 
     
     
         14 . A cartridge for an e-vapor device, comprising:
 a housing including
 a reservoir portion, and 
 a connector portion, the connector portion configured to connect the cartridge to a power supply section; and 
   a heater assembly in the housing, the heater assembly including a dual heating element including,
 a first heating element, and 
 a second heating element stacked on the first heating element, each of the first heating element and the second heating element including a planar portion, the planar portion including,
 a filament defining an air channel through a central portion of the planar portion, the filament extending in a circular shape about the air channel, the filament arranged so as to form a plurality of u-shaped portions extending radially from the air channel, and a first one of the plurality of u-shaped portions being beside a last one of the plurality of u-shaped portions, each of the plurality of u-shaped portions including a tip and an end section opposite the tip, the end section of each of the plurality of u-shaped portions adjacent the air channel, the end section of each of the plurality of u-shaped portions having a first width, and the tip of each of the plurality of u-shaped portions having a second width greater than the first width. 
 
   
     
     
         15 . The cartridge of  claim 14 , wherein the first heating element and the second heating element are electrically connected via welding, soldering, or a pressure-based connection. 
     
     
         16 . The cartridge of  claim 14 , wherein the tip of each of the plurality of u-shaped portions extends away from the air channel. 
     
     
         17 . The cartridge of  claim 14 , wherein each of the first heating element and the second heating element further comprises:
 a first lead portion; and   a second lead portion, the first lead portion and the second lead portion extending away from the planar portion.   
     
     
         18 . The cartridge of  claim 17 , wherein
 the planar portion, the first lead portion, and the second lead portion are a unitary body,   the first lead portion is connected to the first one of the plurality of u-shaped portions, and   the second lead portion is connected to the last one of the plurality of u-shaped portions, such that the first lead portion is beside the second lead portion at a point of connection to the planar portion.   
     
     
         19 . The cartridge of  claim 17 , wherein the first lead portion and the second lead portion at least partially surround the planar portion. 
     
     
         20 . The cartridge of  claim 17 , wherein
 the first lead portion includes a first tip,   the second lead portion includes a second tip,   the first tip and the second tip are on opposite sides of the planar portion, and   the first tip of the first lead portion and the second tip of the second lead portion are bent in a direction that is perpendicular to the planar portion.   
     
     
         21 . The cartridge of  claim 14 , wherein
 a width of the filament varies along a length thereof, and   a space between adjacent ones of the plurality of u-shaped portions gradually increases in a direction away from the air channel.   
     
     
         22 . The cartridge of  claim 14 , wherein
 the reservoir portion includes a porous substrate and the reservoir portion is configured to store a pre-vapor formulation, and   the porous substrate is in fluid communication with a pre-vapor formulation and is placed between the first heating element and the second heating element such that the dual heating element uniformly heats both sides of the porous substrate.